Upper with Zonal Contouring and Fabrication of Same

ABSTRACT

A composite panel portion of an upper may include a contouring element located between a backing and an outer panel. The outer panel conforms to the contouring element and the backing so as to form a raised contour.

BACKGROUND

It is sometimes desirable to include contoured regions in a footwearupper. In some cases, such contouring may be for aesthetic reasons. Forexample, a shoe designer might wish to include raised portions on a shoeupper to enhance certain lines, to create a certain look, to emulate aproduct logo, or for any of various reasons. In other cases, contouringis added for functional reasons. Raised regions might be added toincrease padding in certain areas, to stiffen certain areas, to provideincreased foot support, or for other purposes. In still other cases,contours may be added for both functional and ornamental purposes.

Adding contours to a shoe upper can present challenges, particularlywhen those contours are created by attaching extra elements to theoutside of an upper. Such elements may tend to separate from the upper.Although the attachment of such an element can be reinforced withstitching, this can increase manufacturing cost and/or detract from theshoe appearance. Including contours in an athletic shoe upper can beespecially challenging, particularly when an upper is to be formed fromrelatively thin, lightweight material.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the invention.

In at least some embodiments, a composite panel portion of an upperincludes a contouring element located between a backing and an outerpanel. The outer panel conforms to the contouring element and thebacking so as to form a raised contour. The outer panel can be, e.g., amesh or other flexible porous material and can be bonded to portions ofthe backing adjacent to the contouring element. The composite panel caninclude multiple contouring elements and/or may include one or moreventilation windows defined in the backing and spanned by the outerpanel.

In some embodiments, a composite panel may be formed by assembling astack comprising a backing, a bonding agent, one or more contouringelements and an outer panel. The assembled stack may then be heated andcompressed so as to form a composite panel having a contourcorresponding to the contouring element.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments are illustrated by way of example, and not by way oflimitation, in the figures of the accompanying drawings and in whichlike reference numerals refer to similar elements.

FIGS. 1A through 1C are lateral, medial and top views, respectively, ofa shoe according to some embodiments.

FIG. 2 is an enlarged, partially schematic area cross-sectional viewfrom the location indicated in FIG. 1A.

FIGS. 3A1-3G show various steps in a process for fabricating a compositepanel for the upper of the shoe shown in FIGS. 1A-1C.

DETAILED DESCRIPTION

FIG. 1A is a lateral side view of a shoe 10 according to one exemplaryembodiment. FIG. 1B is a medial side view of shoe 10. FIG. 1C is a topview of shoe 10. Additional embodiments include the upper 11 of shoe 10and/or portions of upper 11, as well as processes for fabricating upper11 or portions thereof. Shoe 10 is a running shoe, but other embodimentsinclude shoes intended for wear by participants in other sporting andnon-sporting activities, as well as uppers for such shoes and processesfor fabrication of such uppers. Although various aspects of shoe 10 arediscussed in detail below, the shapes, sizes and locations of variouselements of shoe 10, as well as other features of shoe 10, merelyrepresent one embodiment. Other embodiments include uppers withdifferent features and/or different combinations, sizes and arrangementsof features, portions of such uppers, shoes incorporating such uppers,and processes for fabricating such uppers.

To assist and clarify subsequent description of various embodiments,various terms are defined herein. Unless otherwise indicated, thefollowing definitions apply throughout this specification (including theclaims). The “interior” of a shoe refers to space that is occupied by awearer's foot when the shoe is worn. The “interior side” (or surface) ofa panel or other shoe element refers to the face of that panel orelement that is (or will be) oriented toward the shoe interior in acompleted shoe. An “exterior side” (or surface) of an element refers tothe face of that element that is (or will be) oriented away from theshoe interior in the completed shoe. In some cases, the interior side ofan element may have other elements between that interior side and theinterior in the completed shoe. Similarly, an exterior side of anelement may have other elements between that exterior side and the spaceexternal to the completed shoe.

Certain regions of a shoe upper can be defined by reference to theanatomical structures of a human foot wearing that shoe, and by assumingthat shoe is properly sized for that wearing foot. One or more of thebelow-defined regions may overlap. The “forefoot” region of an upper isthe portion of the upper that will generally cover the metatarsal andphalangeal bones of the wearer's foot, and which will extend beyond thewearer's toes to the front most portion of the upper. The “midfoot”region of an upper is the portion of the upper that will generally coverthe cuboid, navicular, medial cuneiform, intermediate cuneiform andlateral cuneiform bones of the wearer's foot. The “hindfoot” region ofan upper extends from the midfoot region to the rearmost portion of theupper and covers the wearer heel. The hindfoot region covers the sidesof the calcaneus bone of a wearer and may, depending on a particularshoe configuration, cover some or all of the wearer's talus bone(ankle).

The top forefoot and top midfoot regions of an upper will generallycover the upper surfaces of a wearer's forefoot and midfoot bonesdescribed above. The toe of the upper is the portion that will generallycover the tops and fronts of the toes and that extends from the topforefoot region to the lowest edge of the upper in the direction of thesole. The lateral forefoot region extends between the top forefoot andthe lowest edge of the upper in the direction of the sole and betweenthe toe and lateral midfoot regions. The lateral midfoot region extendsbetween the top midfoot region and the lowest edge of the upper in thedirection of the sole and between the lateral forefoot and hindfootregions. In a similar manner, the medial forefoot region extends betweenthe top forefoot region and the lowest edge of the upper in thedirection of the sole and between the toe and medial midfoot regions.The medial midfoot region extends between the top midfoot region and thelowest edge of the upper in the direction of the sole and between themedial forefoot and hindfoot regions. The topfoot region includes thetop forefoot and top midfoot regions. The lateral side region includesthe lateral forefoot and lateral midfoot regions. The medial side regionincludes the medial forefoot and medial midfoot regions.

Returning to FIGS. 1A-1C, shoe 10 includes an upper 11 that is attachedto a sole structure 12. Embodiments include shoes having sole structuresof numerous widely varying types. A sole structure in some embodimentsmay be, e.g., a single piece molded from synthetic rubber or othermaterial. In other embodiments, a sole structure may include multiplecomponents that have been sequentially molded or otherwise bondedtogether. For example, a sole structure may include a midsole formedfrom a first material (e.g., foamed ethylene vinyl acetate) bonded to anoutsole formed from different materials (e.g., synthetic rubber). A solestructure could also include one or more fluid-filled cushions, astiffening plate or other support element(s), traction elements (e.g.,cleats), etc. For convenience, and because of differing internal detailsof sole structures according to various embodiments, sole structure 12is treated as a single unitary component in FIGS. 1A-1C.

Upper 11 includes a zonally-contoured composite panel 15, portions ofwhich are exposed in the fore- and midfoot regions, and a foxing panel16 in the hindfoot region. Foxing panel 16 includes an ankle collar 17.The hindfoot portion of upper 11 further includes a heel counter (notshown), as well as padding and an inner lining.

Composite panel 15 includes a mesh outer panel 19 that wraps around thesides and front of a foot of a shoe 10 wearer W. So as to avoidobscuring the drawings, outer panel 19 is represented throughout thedrawings as a relatively coarse diagonal grid. In practice, however, thematerial of outer panel 19 can have a much finer weave (or otherpattern) than is represented in the drawings and/or have openings ofother shapes. As but one example, the openings in outer panel 19 couldbe approximately 1 to 2 millimeters in size.

As seen in FIG. 1A, composite panel 15 covers the lateral sides of themidfoot and forefoot. In particular, composite panel 15 extends frombelow the top edge 20 of sole structure 12 on the lateral side, over themid- and forefoot side regions, and under the lateral side of an eyeletreinforcing strip 21. The rear lateral side of composite panel 15extends under the forward lateral edge 22 of foxing panel 16. As shownin FIG. 1B, composite panel 15 also covers the medial sides of thewearer forefoot and midfoot. Similar to the lateral side, the medialside of composite panel 15 extends from below the top edge 20 of solestructure 12, over the mid- and forefoot side regions, and underreinforcing strip 21. The rear medial side of composite panel 15 extendsunder the forward medial edge 26 of foxing panel 16. As seen in FIG. 1C,another portion of composite panel 15 covers the tops of the toes.Composite panel 15 extends under toe cap 25 and under the front ofreinforcing strip 21.

In addition to outer panel 19, composite panel 15 includes a backing 29and contouring elements 31, 32, 33 and 34. As explained in more detailbelow, composite panel 15 is formed by bonding outer panel 19 andcontouring elements 31-34 to backing 29. Contouring elements 31-34 arepositioned between outer panel 19 and backing 29 in composite panel 15.As seen in FIGS. 1A-1C, backing 29 only extends over limited regions ofcomposite panel 15. Openings in backing 29 are spanned by portions ofouter panel 19 and define numerous ventilation windows in upper 11. Toevent window 36 generally corresponds to the tops of the 2nd through 5thproximal and middle phalanges, to at least a portion of the top of the1st proximal phalange, to tops of the distal ends of the 1st through 5thmetatarsals, to the medial side of the 1st proximal phalange and firstmetatarsal distal end, and to the lateral sides of the 5th metatarsaldistal end and 5th proximal phalange. Three vent windows 37-39 arelocated on the medial side (FIG. 1B) and three more vent windows 40-42are located on the lateral side.

Backing 29 further includes an inner border that surrounds a tongueopening 47 and that has an area generally coinciding with the area ofeyelet reinforcing strip 21. The inner border of backing 29 is notvisible in FIGS. 1A-1C but is shown in FIG. 3A1. Numerous bands bridgethe inner border of backing 29 and the bottom regions of composite panel15, below edges 20 of sole structure 12, joined to a lasting sock (notshown). On the medial side, and as seen in FIG. 1B, bands 51, 52, 53 and54 form an “M” shape. Similarly, and as seen in FIG. 1A, bands 55, 56,57 and 58 form another “M” shape on the lateral side. In the embodimentof shoe 10, bands 51-54 and 55-58 provide additional reinforcement inside portions of upper 11 adjacent the shoe laces and limit the stretchof upper 11 in those side portions.

In the embodiment of shoe 10, each of contouring elements 31-34 has aninverted “V” shape. As shown in FIG. 1B, contouring element 31 islocated between the exterior sides of backing element 29 bands 51 and 52and the interior side of outer panel 19. Contouring element 32 islocated between the exterior sides of backing element 29 bands 53 and 54and the interior side of outer panel 19. As seen in FIG. 1A, contouringelement 33 is located between the exterior sides of backing element 29bands 55 and 56 and the inner side of outer panel 19. Contouring element34 is located between the exterior sides of backing element 29 bands 57and 58 and the interior side of outer panel 19.

In the embodiment of shoe 10, upper 11 does not include a “bootie” orother liner in the region of composite panel 15. Thus, there is nothingseparating a socked foot of wearer W and the interior sides of theportions of outer panel 19 spanning windows 36-42. In this manner,greater ventilation can be achieved. In other embodiments, a bootie orother type of liner can be included.

FIG. 2 is an enlarged, partially schematic area cross-sectional viewtaken from the location indicated in FIG. 1A and showing the structureof composite panel 15. Backing 29 is located on the interior side ofupper 11. Contouring element 33 and outer panel 19 are bonded to theexterior side of backing 29. Outer panel 19 may also be bonded to theexterior surface of contouring element 33 and to exterior surfaces ofcontouring elements 31, 32 and 34. Alternatively, the interface betweenouter panel 19 and the exterior surfaces of contouring elements 31-34may lack glue or other bonding agent.

Outer panel 19 tightly conforms to contouring element 33. Tension inouter panel 19 causes outer panel 19 to exert inward pressure oncontouring element 33. This causes a slight compression of contouringelement 33 and a rounding of the contouring element outer edges (e.g.,edges e1). Outer panel 19 is bonded to the portions of backing 29 band55 surrounding contouring element 33, with the bond between panel 19 andband 55 extending to inner edges e2 where contouring element 33 meetsband 55. Outer panel 19 is similarly bonded to the portions of band 56surrounding contouring element 33 and to the portions of the other bandssurrounding the other contouring elements. Thus, outer panel 19 tightlyconforms to the other portions of contouring element 33 and tocontouring elements 31, 32 and 34 in a manner similar to that shown inFIG. 2.

In the embodiment of shoe 10, contouring elements 31-34 aresubstantially thicker than backing 29 and outer panel 19. In someembodiments, the thickness TC of contouring elements 31-34 is equal toor greater than the thickness TB of backing 29 and equal to or greaterthat the thickness TO of outer panel 19. In certain embodiments, thecontouring element thickness is equal to or greater than the combinedthicknesses of the backing and outer panel (i.e., TC≧TB+TO).

Although panel 19 of composite panel 15 is referred to as an “outerpanel,” panel 19 need not be the outermost panel of composite panel 15.In the embodiment of shoe 10, some portions of the outer panel 19exterior surface are covered by toe cap 25 and by reinforcing strip 21.Other portions are covered by foxing panel 16. Other components couldalso be attached over other portions of the outer panel 19 exteriorsurface. Similarly, backing 19 need not be the innermost component ofcomposite panel 15. Moreover, contouring element 33 need not be directlybonded to backing 29. In some embodiments, for example, another panel, astiffener or some other element could be interposed between the interiorface of a contouring element and the exterior face of a backing.

The construction shown in FIG. 2 offers several advantages. It is oftendesirable to include raised ridges or other types of surface contours ina footwear upper. Such contours may have aesthetic and/or functionalpurposes. For example, zones of increased thickness may provideadditional support and/or additional cushioning in certain regions.Adding surface contours presents certain challenges when using meshesand other types of lightweight materials, however. Stitching acontouring element to a mesh material can be difficult, particularlywith meshes having more open weave patterns. Moreover, stitchingoperations can be time consuming and expensive, and thus it is oftendesirable to minimize the amount of stitching needed.

Bonding or stitching a contour element to the outside of a mesh or otherlightweight upper material can also present problems. A contour elementthat is attached in such a fashion may be prone to separation. If aninterface between a contour element and an exterior face of an upper isexposed, that interface might be snagged as a wearer foot brushesagainst external objects. As a result, the contour element might beginto separate from the upper. With the construction shown in FIG. 2,however, the interface between the contouring element and backing 29(e.g., edges e2) is protected by outer panel 29. By locating thecontouring elements on the interior side of a lightweight material andtightly conforming that material to those contouring elements, there isless potential for separation. As a result, contouring elements areattached in a more secure manner.

Simply attaching a contour element to the outer surface of a mesh panelmight also have other disadvantages. Such an attachment might beaesthetically unpleasing and result in an upper with an unfinishedand/or ragged look. Conforming a mesh or other lightweight panel to acontouring element permits creation of an upper with a more finishedoverall appearance. For example, a mesh pattern that extends across muchof an upper can be overlaid onto the contour element. This helps blendthe contour elements with other portions of the upper. Moreover, thetension of the mesh material on the surface of a contour element canhelp soften the edges of the contour element and give it a more roundedappearance.

FIGS. 3A1 through 3G show a process, according to at least someembodiments, to fabricate composite panel 15 of upper 11. In a firststep shown in FIG. 3A1, backing 29 is placed onto an assembly jig 60.Jig 60 includes a flat surface 61 having multiple pins 62 that extendperpendicularly from surface 61. In the top plan view of FIG. 3A1, pins62 extend out of the plane of the drawing. So as to distinguish pins 62from unlabeled eyelet holes shown in backing 29, the tops of pins 62 arerepresented as filled-in black circles.

Each of pins 62 is pushed through corresponding holes in one or morecomponents of composite panel 15 as those components are added to astack of components being assembled on surface 61. This allows properpositioning of those components relative to one another. In FIG. 3A1,backing 29 has been placed by pushing backing 29 onto surface 61 so thatpins 62 are pushed through corresponding locating holes in backing 29.FIG. 3A2 is a side view of jig 60 and backing 29 from the locationindicated in FIG. 3A1. Backing 29 has been placed onto surface 61 andpins 62 extend upward from surface 61 through backing 29.

As previously indicated, backing 29 includes an inner border 65 thatsurrounds tongue opening 47. Also seen in FIG. 3A1 are lateral sidebands 55-58 and medial side bands 51-54. Vent windows 36-42 are alsovisible in FIG. 3A1. Surface 66 of backing 29 will be the exteriorsurface of backing 29 in the completed upper.

Numerous types of materials can be used for backing 29. In theembodiment of shoe 10, backing 29 is a polyester knit material having alayer of unactivated hot melt bonding agent pre-applied to surface 66.In other embodiments, a backing material may not include a pre-appliedhot melt agent layer. Instead, a separate layer of hot melt bondingagent material having the same shape as backing 29 could be placed oversurface 66 after backing 29 has been placed on jig 60. In someembodiments, a backing may have a thickness (TB from FIG. 2) ofapproximately 0.5 millimeters.

In a next step, and as shown in FIG. 3B, pre-cut contouring elements 31,32, 33 and 34 are put into place on portions of backing 29 surface 66.In particular, each of contouring elements 31-34 has been placed bypushing the contouring element onto surface 66 so that appropriate onesof pins 62 are pushed through corresponding locating holes in thecontouring element. In the embodiment of shoe 10, each of contouringelements 31-34 is formed from a synthetic leather and has a thickness(TC from FIG. 2) of between approximately 1 millimeter and approximately3 millimeters. In some embodiments, the exterior surfaces of contouringelements 31-34 may have a pre-applied layer of unactivated hot-meltbonding agent. In other embodiments, separate pieces of hot-melt bondingagent material having the same shape as the contouring elements may beplaced onto the exterior surfaces of the contouring elements. In stillother embodiments, there is no hot-melting bonding agent between theexterior surface of the contouring elements and portions of the outerpanel 19 interior surface that contact those contouring element exteriorsurfaces.

In a subsequent step, and as shown in FIG. 3C, outer panel 19 is putinto place by pushing outer panel 19 onto jig 60 so that pins 62 arepushed through corresponding holes in outer panel 19. In the embodimentof shoe 10, outer panel 19 is a relatively fine mesh (e.g., havingopenings of approximately 1 mm or smaller) formed from a woven syntheticmaterial. Other embodiments utilize other types of flexible porousfabrics for outer panel 19. Such other types of flexible porous fabricscan include, e.g., woven and non-woven meshes formed from syntheticand/or nonsynthetic materials and/or having finer or coarser meshpatterns, various types of textile materials, and other porousmaterials.

At the conclusion of the step shown in FIG. 3C, backing 29, contouringelements 31-34 and outer panel 19 have been assembled into a stack 70onto jig 60. At this stage, the individual components of stack 70 arenot yet bonded to one another. If stack 70 were to be removed from jig60 in this unbonded condition, great care would be needed to keep thecomponents in their desired relative positions. In a subsequent step,and as shown in FIG. 3D1, jig 60 is placed under a heated press platen72 as part of a first pressing operation. As shown in FIG. 3D2,sufficient heat and pressure are applied by platen 72 so as to at leastpartially activate the hot-melt bonding agent on backing 29. Thisresults in a partial bonding of backing 29, contouring elements 31-34and outer panel 29 that temporarily allows these components to remain inan assembled configuration when stack 70 is removed from jig 60.Although not shown in FIG. 3D1 or 3D2, platen 72 may include holes orrecesses corresponding to and accommodating pins 61.

The temperature, pressure and press time for the first pressingoperation of FIG. 3D1 will vary based on the type of materials used. Insome embodiments utilizing the example materials identified above, theassembled components stack is pressed at 150° C. and 100 kg/cm² forapproximately for 15 seconds. For different types of materials,appropriate pressing parameters to achieve a partial component bondingis readily determinable by persons of ordinary skill in the art. As butone example, samples of components to be used could be assembled andsubjected to the press parameters described above. If insufficientpartial bonding results, additional sample assemblies can be preparedand pressed at increasingly higher temperatures (e.g., in 5° C.incremental increases) and or pressures (e.g., in 2 kg/cm² incrementalincreases) until the desired result (partial bonding sufficient toretain component arrangement prior to second pressing) is achieved.

In a subsequent step shown in FIG. 3E1, the partially bonded stack 70 isremoved from jig 60 and placed onto a heat-transferring silicone pad 73on a heated lower platen 74 of a second press. Another heat-transferringsilicone pad 75 is attached to a heated upper platen 76 of that press.Sheets of release paper (not shown) could be placed between partiallybonded stack 70 and pads 73 and 75. The partially bonded stack 70 isthen pressed between platens 74 and 76 (FIG. 3E2). Heat from platens 74and 76 is transferred to stack 70 through pads 73 and 75. Because pads73 and 75 are partially compressible, however, outer panel 19 can bepressed into close conformance to backing element 29 and contouringelements 31-34 (e.g., as shown in FIG. 2).

The temperature, pressure and press time for the second pressingoperation of FIG. 3E2 will also vary based on the type of materialsused. In some embodiments utilizing the example backing, contouringelement and outer panel materials identified above, partially-bondedstack 70 is pressed at 150° C. and 35 to 40 kg/cm² for approximately for30 seconds. For different types of materials, appropriate pressingparameters to achieve a complete component bonding (as shown in FIG. 2)is readily determinable by persons of ordinary skill in the art. As butone example, after determining process parameters for a first pressingas described above, a sample of partially bonded components could becreated and subjected to the second pressing parameters described above(e.g., 150° C., 35-40 kg/cm², approximately 30 seconds). If insufficientbonding or insufficient conformance of the mesh to the backing andcontouring elements occurs, additional samples of the partially-bondedcomponents can be prepared and pressed at increasingly highertemperatures (e.g., in 5° C. incremental increases) and/or pressures(e.g., in 2 kg/cm² incremental increases) and/or for increased timeperiods (e.g., in 5 second incremental increases) until the desiredresult (complete conformal bonding of mesh to backing and contouringelements) is achieved.

At the conclusion of the second pressing operation, stack 70 has beentransformed into composite panel 15. Outer panel 19 is bonded to backing29 and tightly conforms to contouring elements 31-34. FIG. 3F showscomposite panel 15 after removal from the press of FIGS. 3E1 and 3E2.Although not visible in the view of FIG. 3F, composite panel 15 hascontours corresponding to contouring elements 31-34. Specifically, outerpanel 19 is bonded to backing 29 and conforms to the exterior surfacesof each of contouring elements 31-34 in a manner similar to that shownin FIG. 2, thereby creating raised elements that will be located on theexterior surface of a completed upper.

Subsequently, and as shown in FIG. 3G, toe cap 25 and reinforcing panel21 are attached to composite panel 15. In some embodiments, toe cap 25and reinforcing panel 21 are stitched in place. Eyelet holes in panel 21align with corresponding eyelet holes in backing 29. Portions of mesh 19covering eyelet holes in backing 29 can be cleared in a punchingoperation (not shown). In some embodiments, panel 21 and toe cap 25could be glued or otherwise bonded to composite panel 15. For example,panel 21 and toe cap 25 could include a layer of unactivated hot-meltadhesive material on their interior surfaces and be bonded to compositepanel 15 in a heated press. In still other embodiments, panel 21 and/ortoe cap 25 could be assembled with the components of composite panel 15(e.g., in a step between the steps shown in FIGS. 3C and 3D1) and thenbonded in the first and second pressing steps. In the embodiment of shoe10, panel 21 and toe cap 25 are formed from synthetic leather. In atsome embodiments, panel 21 and/or toe cap 25 could be formed of one ormore other materials (e.g., natural leather, polyurethane (PU),thermoplastic polyurethane (TPU), a mesh material, etc.).

After attachment of reinforcing panel 21 and toe cap 25, rear edge 75 ofcomposite panel 15 is joined (e.g., by stitching) to rear edge 76 so asto form a shell of upper 11. Foxing panel 16 (with attached collar 17),padding and a heel counter are then joined to the shell by stitchingand/or bonding. Foxing panel 16 can be formed in a separate operation ina manner known in the art. Tongue 13 is then attached to the shell andthe shell placed on a last. A lasting sock (or Strobel) can then beattached to the lasted shell to complete upper 11, and sole structure 12attached.

As can be appreciated from the foregoing, techniques described hereinpermit simple fabrication of an upper (or portion of an upper) withzonally-specific contours. The resulting upper (or upper portion) caninclude one or more contouring elements that are securely located on theinterior side of a lightweight panel and that lack exposed interfacesthat promote separation of the contouring element.

Shoe 10 and the fabrication operations described above are merelyexamples of products and processes according to some embodiments. Otherembodiments include numerous other materials and material combinations.For example, a backing could be formed from synthetic leather or fromsome other material different from polyester knit material. Instead ofsynthetic leather, strips of EVA (ethylene vinyl acetate) foam, TPUfoam, other types of foam, non-foamed materials, natural leather, orother materials could be used for contouring elements. As indicatedabove, various types of meshes and other porous fabrics could beemployed. A single upper might also include combinations of multiplebacking materials, combinations of multiple contouring element materialsand/or combinations of multiple mesh (or other porous fabric) materials.Additional layers and/or components could also be added. For exampleadditional PU or TPU coated panels similar to toe cap 25 and/orreinforcing panel 21 could be attached to an upper in other locations.

Other embodiments may also include different shapes and/or arrangementsof various components. Ventilation windows could be larger or smaller,fewer or more numerous, have different shapes and locations, etc.Contouring elements could also have different shapes, thicknesses,locations, etc. Other embodiments may have a foxing panel with adifferent shape and/or having different internal padding. In someembodiments, a separate foxing panel might be omitted.

Additional fabrication techniques can also be employed. In someembodiments, only a single pressing operation is performed. As oneexample thereof, a first pressing operation to temporarily bondcomponents is omitted. Instead, a dual pan assembly jig such as isdescribed in commonly-owned U.S. patent application Ser. No. 12/603,494(incorporated by reference herein) is employed.

The foregoing description of embodiments has been presented for purposesof illustration and description. The foregoing description is notintended to be exhaustive or to limit embodiments of the presentinvention to the precise form disclosed, and modifications andvariations are possible in light of the above teachings or may beacquired from practice of various embodiments. As but one example,techniques such as are described herein can be used to fabricatearticles other than footwear uppers. The embodiments discussed hereinwere chosen and described in order to explain the principles and thenature of various embodiments and their practical application to enableone skilled in the art to utilize the present invention in variousembodiments and with various modifications as are suited to theparticular use contemplated. Any and all combinations, subcombinationsand permutations of features from above-described embodiments are thewithin the scope of the invention.

1. A portion of an upper, comprising: a backing; a contouring element;and a porous outer panel, wherein the backing and the outer panel eachhas an interior side configured to face toward an interior space of anarticle of footwear, and an exterior side configured to face away fromthe interior space, when the upper is incorporated into the article offootwear, the contouring element is located between the exterior side ofthe backing and the interior side of the outer panel, and the backing,the contouring element and the outer panel form a bonded composite panelin which the outer panel conforms to the contouring element and thebacking so as to form a raised contour.
 2. The upper portion of claim 1,wherein the outer panel has a thickness less than a thickness of thecontouring element, and wherein regions of the outer panel interior sidenot contacting the contouring element are bonded to regions of thebacking exterior side not contacting the contouring element.
 3. Theupper portion of claim 1, wherein regions of the outer panel overlayingthe contouring element are under tension and deform the contouringelement.
 4. The upper portion of claim 1, wherein the outer panelcomprises a mesh.
 5. The upper portion of claim 4, wherein the backingincludes at least one opening defining a ventilation window, and whereina portion of the mesh spans the ventilation window and is bonded toregions of the backing exterior side at an edge of the ventilationwindow.
 6. The upper portion of claim 4, wherein the backing includesopenings defining a plurality of ventilation windows, each of theventilation windows is spanned by a corresponding portion of the mesh,and each of the window spanning mesh portions is bonded to regions ofthe backing exterior side at edges of the corresponding ventilationwindow.
 7. The upper portion of claim 4, further comprising a secondcontouring element located between the exterior side of backing and theinterior side of the mesh, wherein the second contouring element issurrounded by adjacent regions of the backing exterior side notcontacting the second contouring element, and the adjacent backingregions surrounding the second contouring element are bonded to theinterior side of the mesh.
 8. The upper portion of claim 1, wherein thecontouring element is surrounded by adjacent regions of the backingexterior side not contacting the contouring element, and wherein thesurrounding adjacent regions are bonded to the interior side of theouter panel.
 9. The upper portion of claim 1, wherein the contouringelement has a thickness greater than the combined thicknesses of theouter panel and of the backing.
 10. The upper of claim 9, wherein thebacking includes at least one ventilation window, and wherein a portionof the flexible porous fabric spans the ventilation window and is bondedto regions of the backing exterior side at an edge of the ventilationwindow.
 11. The upper portion of claim 9, wherein the contouring elementis surrounded by adjacent regions of the backing exterior side notcontacting the contouring element, and wherein the surrounding adjacentregions are bonded to the interior side of the outer panel.
 12. Theupper portion of claim 11, wherein the outer panel comprises a mesh. 13.The upper portion of claim 12, wherein regions of the outer paneloverlaying the contouring element are under tension and deform thecontouring element.
 14. A portion of an upper for an article offootwear, comprising: a backing; a contouring element; and a porousouter panel, wherein the backing and the outer panel each has aninterior side configured to face toward an interior space of an articleof footwear, and an exterior side configured to face away from theinterior space, when the upper is incorporated into the article offootwear, the contouring element is located between the exterior side ofthe backing and the interior side of the outer panel, and the outerpanel is bonded to portions of the backing exterior side and isconformed to the contouring element along multiple interface edges ofthe backing and the contouring element.
 15. The upper portion of claim14, wherein the porous outer panel comprises a mesh.
 16. The upperportion of claim 14, wherein the backing includes at least one openingdefining a ventilation window, and wherein a portion of the outer panelspans the ventilation window and is bonded to regions of the backingexterior side at an edge of the ventilation window.
 17. The upperportion of claim 14, wherein the backing includes a plurality ofopenings defining ventilation windows, each of the ventilation windowsis spanned by a corresponding portion of the outer panel, each of thewindow spanning outer panel portions is bonded to regions of the backingexterior side at edges of the corresponding ventilation window, theupper portion includes a second contouring element located between theexterior side of backing and the interior side of the outer panel, thesecond contouring element is surrounded by adjacent regions of thebacking exterior side not contacting the second contouring element, andthe adjacent backing regions surrounding the second contouring elementare bonded to the interior side of the outer panel.
 18. A methodcomprising: assembling a stack of components comprising a backing, abonding agent, at least one contouring element and a porous outer panel,wherein the contouring element is located between the backing and theporous outer panel; and heating and compressing the assembled stack soas to bond the backing, contouring element and outer panel and form acomposite panel having a contour corresponding to the contouringelement.
 19. The method of claim 18, wherein the stack of componentscomprises a contouring element having a thickness greater than athickness of the porous outer panel.